Procedure for Improving the Ground System{4459, 7423} Caterpillar

Power Module:

PM3516 (S/N: NAM1-UP; KEN1-UP)

Introduction

Illustration 1	g02022307
Controls for the XQ2000 generator for manual paralleling

Illustration 2	g02022313
Controls for the XQ2000 generator for auto paralleling

This Special Instruction will guide the user with the improvements in the ground system.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Instructions for modifying XQ2000 Package

Perform the following procedure for improving the ground system in order to minimize electrical noise and the spike in the battery voltage:

• The container must be bonded to ground of the power module.

• All electronic modules with case ground must be grounded.

• The engine block must be bonded directly to ground of the power module.

• Add instruction for proper grounding of the shore power.

• Add a ground label at both the ground bar of the customer and on the generator frame.

The container must be bonded to ground of power module

Illustration 3	g02126440

Connect a 301-0562 Cable As , wire (Green/Yellow-3) between the ground bar of the customer and the container. Remove the paint at the connection of the container before connecting the 301-0562 Cable As .

All electronic modules with case ground must be grounded

Illustration 4	g02126439

Illustration 5	g02126441

Connect a ground wire (Green/Yellow-14) between the ground stud of the discrete input output module and the ground stud of the control panel. Inspect the EMCP 3 for good case ground.

The engine block must be bonded directly to ground of power module

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Illustration 6	g02123496

1. Check for the availability of a cable between the negative terminal of the engine starter and the engine block. If a cable is found, remove the cable so that the engine block will be bonded directly to the ground of the power module.

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Illustration 7	g02126443
(1) Ground cable (2) Black flexible conduit (3) Rail

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Illustration 8	g02123995
(4) Ground cable termination

2. Install a new bonding cable (Green/Yellow-4) (1) between the engine block and the ground bar inside the terminal box. The new cable is enclosed in a black flexible conduit (2) .

Instruction for proper grounding of shore power

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Illustration 9	g02126444

1. The ground terminal of the shore power should not be used, while the unit is in service. When the unit is in service, the shore power equipment will be grounded through the ground bar of the power module to the earth ground.

2. The ground terminal of the shore power should be used during the following situations:
   • The unit is not in service.

   • The shore power is supplied to the unit.

   The system ground to the ground terminal of the shore power will serve as the ground of the shore power equipment, when the ground terminal of the shore power is used.

   Note: A warning label is provided near the ground terminal in order to alert the user regarding the potential misapplication of the ground terminal.